Ewald Wachmann Joint EC / European Green Cars Initiative Workshop 2013, Brussels 10 ... · 2018. 1. 9. · Ewald Wachmann Joint EC / European Green Cars Initiative Workshop 2013,

Ewald Wachmann

Joint EC / European Green Cars Initiative

Workshop 2013, Brussels

10 April 2013

Energy STorage with lowered cost and improved

Safety and RELIAbility for electrical vehicles Coordinator/ Partners: May 2011 – April 2014 Austria: France: Germany: Italy:

Joint EC / European Green Cars Initiative Workshop 2013 10. April 2013

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Safety

Longterm Battery Lifetime

High Costs

New Safety sensors

New BMS concepts

Ultra caps

Cost-efficient BMS ICs

and safety components

Concerns for electrical cars


Battery Monitoring and

Management Software for

dynamical configuration Battery Monitoring

and

Active Balancing IC,

galvanic isolated

interface IC

New low cost

Power Antifuses

Gas Sensor for

Safety Monitoring

Li-Ion Battery

Ultra Capacitor battery pack power pack extension for Li-Ion

batteries

New high density

ultra capacitors

new MEMS based

spark detection

sensor


New Developments

Result of the study with simulations and first test samples:

The integration of the antifuse on a battery cell element is possible

The structure of the device has been defined to enable antifusing

Voltage inversion of the battery cell provides enough current to activate antifusing

Development of new antifuse devices


Specifications:

Category Value Comment

Maximum current 100 A

Maximum leakage / self discharge current <5 mA 10% self discharge per month for a

40Ah cell

Maximum series resistance 1 mOhm 10 W dissipation at 100 A

Assembly and contacting section 5.3 mm² 20mm long Aluminum: a wire of 0.1mΩ

requires a X-section of 5.3mm²

Untriggered antifuse fusing technology Aluminum spiking

Externally triggered antifuse fusing technology Exothermic reaction

Material costs < 0.20 €

Development of new antifuse devices


based on Air Classification Module (ACM)

Terminals (3x)

PCB O-ring

Pall membrane

Springs (3x)

MQS connector

MEMS gas sensor

Membrane with

electrodes and

sensitive layer

Development of Li-Ion battery emission sensor


Gas sensors at Li-cell abuse tests

Cell

Actuator

Gas sensors

Nail

Stress Tests

-Nail penetration test

-Overcharging

-Short-circuit

Automotive sensors

-Volatile organics sensor

-Hydrogen sensor

Automotive pouch cells

-LiFePO4, 10Ah

-LiMnO2, 20Ah

-LiCoO2, 5Ah



200 250 300 350 400 450 500 550 600 650 700

0

20

40

60

80

100

1400

1500

1600

0

10k

20k

30k

40k

05

1015202530

time [s]

Tce

ll [°C

]

H2 [m

V]

VO

C [a

u]

Uce

ll [V]

cell voltage

VOC

Hydrogen

cell temp.

LiCoO2 pouch cell, 5Ah, I=60A

310⁰C

max

42 sec.

Overcharging

signal for shutdown



Further tests ongoing and show promising results


Tests @ FhG and in final

demonstrator ongoing …

Li-Ion battery

module assembly


Li-Ion cell demonstrator with BMS, sensors & fuse cells

EMC critical environment

Split communication in 2 domains

Daisy Chained direct action signals for Diagnosis, Trigger, Clock

Daisy Chained low speed serial communication for cell voltage broadcast and to read

cell data at widely spaced time slots

Go for autonomous balancing through simultaneous

comparison of cell voltages with a reference

more accurate compared to sequential measurement

synchronization with current not needed

Either passive or active balancing through

integrated switches

New cell balancer and monitor IC


Cell Balancer / Monitor Supports 3-7 cells for cell voltages from 1,8V to 4,5V

Simultaneous and autonomous cell monitoring - digital or analog reference

Autonomous balancing through simultaneous cell voltage capture and comparison with

reference

Either passive balancing or active balancing through small external fly back converter

40pin QFN package

Diagnosis functions:

• Connected cells

• cell voltage ok

• balance done

• temperature ok

• absolute temperature

• absolute cell voltage

• status data

C-GND

Comp7

Comp6

Comp5

Comp4

Comp3

Comp2

Comp1

5V

5V

5V

5V

5V

5V

5VC_out1

C_out2

C_out3

C_out4

C_out5

C_out6

C_out7

0V

0V

0V

0V

0V

0V

0V

Vref

Vref

Vref

Vref

Vref

Vref

Vref

Vref

VCELL1

VCELL2

VCELL3

VCELL4

VCELL5

VCELL6

VCELL7

Cell1_V1

Cell2_V2

Cell3_V3

Cell4_V4

Cell5_V5

Cell6_V6

Cell7_V7

Cnt1H

Cnt2L

Cnt7H

Cnt1L

Cnt2H

Cnt3L

Cnt3H

Cnt4L

Cnt4H

Cnt5L

Cnt5H

Cnt6L

Cnt6H

Cnt7L

Cnt1

Cnt2

Cnt3

Cnt4

Cnt5

Cnt6

Cnt7

V5V

CELL-THUanalog option

CELL-THLanalog option

CVT-NOK-OUT

CVT-NOK-IN

CLK-IN

CLK-OUT

BD-OUT

BD-IN

MS-SL

TEMP-IN1

TRIG-IN

TRIG-OUT

RC

Osc

Temp

sensor/

s/w

cap ckt

FSM,

DIGITAL,

SAR ADC

Logic

3V

5V

3V

0V

0V

0V

Pre_Reg,

POR,LDO

0V

VUSP

Cell OK,

LS,OTM

0V

42V5V

SDI SDOSCLK CS

VSUP FD

-IN

FD

-OU

T

V5

V-I

N

PPTrim

5V

0V

TS

EC

H

TS

EC

L

WAKE_IN

CLK TO

COMPAR

ATOR

5V

0V

TEMP-IN2

DAC

High

precision

reference

DAC_IN

5V

0V

CLK level

shifter to

sample cell

voltage

Vcell

0V

SSW

_LS

VCELL

REF_T

WA

KE

_O

UT

NCGNDGNDVREF

_IN

VREF

_H

VSUP

Vref_H

uC

uC

uC

To GND

for Master,

To VSUP

for Slave

uC

R discharge for passive

option

Compoments for active

balancing option

Signal connections in

chained system

analog Vref option

analog treshold/ref

option



AS8506 Specifications

Test board for autonomous

battery balancing with

AS8506



Example of 3 cell balancing

Active balancing for 3 cells



• Most bottom IC is configured as Master,

others are Salves (up to 31 slaves)

• Communication through Master SPI

• Chained 3 wire SPI communication from

master to slaves

• Synchronized autonomous monitoring

and balancing on Trigger

• When active balancing:

– One transformer for up to 14 cells

– Charge redistribution if energy is taken

from pack

– Isolated driver for slaves >14 cells

14 cell application example


Stacked BMS ICs


Electro kart: daisy-chain communication demonstrated!

Development of Ultra Caps

New Ultra Cap cells

delivering energy

densities in the range

of 7-9 Wh/l

Final module

assembly started


Development of Ultra Caps

• Measurements taken for

delivered cells

• Model matches leakage

current and self-discharge

behavior of cells @ 25C

• Single cell model can be

integrated into overall system

electrical simulation

• Pack simulation implemented

by placing multiple cells in

series.


• New BMS ICs for an integrated flexible battery management system enabling simultaneous cell compare and active cell balancing for ultra capacitors and Li-Ion cells: daisy-chaining demonstrated assembly into demonstrator

• new cost effective power antifuse for dynamical configuration of energy storage units: prototype building

• safety sensors: new gas sensor with high sensitivity and fast response and new MEMS based spark detection sensor to improve safety monitoring of energy storage systems: tests demonstrating early sensing capability

• new ultra capacitor power cell with 50% higher energy density: prototypes available

• new high voltage (several kV) capable test and characterization equipment and galvanic isolated BMS driver ICs: verification tests ongoing


Thank you for your attention!

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www.estrelia.eu


http://www.estrelia.eu/

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Ewald Wachmann Joint EC / European Green Cars Initiative Workshop 2013, Brussels 10 ... · 2018. 1. 9. · Ewald Wachmann Joint EC / European Green Cars Initiative Workshop 2013,